Automatic anode winding machine



Dec. 17, 1968 E. r. ALLEN AUTOMATIC ANODE WINDING MACHINE 3 Sheets-Sheet 1 Filed Sept. 9, 1966 mvsm'on EDWIN T. ALLEN BY (if Dec. 17, 1968 E. T. ALLEN AUTOMATIC A NODE WINDING MACHINE 3 Sheets-Sheet 2 Filed Sept'. 9, 1966 INVENTOR EDWIN 7'. A LLEN ATTORNEY Dec. 17, W68 E. T. ALLEN AUTOMATIC ANODE WINDING MACHINE 3 Sheets-Sheet 5 Filed Sept. 9, 1966 Fmz INVENPOR EDWIN If ALLEN ATTORNEY United States Patent 3,416,215 AUTOMATIC ANODE WINDING MACHINE Edwin T. Allen, Lexington, NC, assignor to P. R.

Mallory & Co. Inc., Indianapolis, Ind., a corporation of Delaware Filed Sept. 9, 1966, Ser. No. 578,282 6 Claims. (Cl. 29204) This invention relates to a machine for automatically manufacturing an anode for batteries. More particularly it relates to a machine for manufacturing such an anode which is formed from spirally wound alternating layers of metallic anode material that is corrugated, an absorbent material, and a suitable casing. I

In order to get a clear understanding of the invention it should be noted that an anode winding machine of the above type is normally entirely automatic in operation and should require no attention other than the replacement of the reels of absorbent material, casing and the anode foil when they are exhausted. Further where a single mechanical failure, such as the breaking of one of the relatively fragile metal anode foils goes unnoticed for a long period of time, an utterly worthless product may be produced with a resultant serious loss of material and time.

For further understanding of the invention, it should be understood that anodes for batteries are often times severely limited in size. This leads to the problem of providing a maximum amount of anode surface area in a limited space. This problem is usually solved by corrugating the metallic foil. In addition, such corrugating serves to provide space between layers of the material for passage of the electrolytic medium. Therefore, any efiicient winding machine must of necessity provide for such corrugating of the metallic foil without breaking the foil.

Additionally, an efficient winding machine should provide means for automatically and efiiciently forming a casing for the alternate layers of spirally wrapped metallic foil and absorbent material such that the layers can be maintained in a relatively uniformly held cylindrical shape.

It is, therefore, an object of the present invention to provide an automatic winding machine which will automatically form a battery anode composed of spirally wrapped alternating layers of metallic foil and absorbent material enclosed in a suitable casing.

Another object of the invention is to provide such a machine wherein means are provided to corrugate the metallic foil as it is being wound.

Another object of the invention is to provide in such a machine a means for so wrapping the foil without fear of breaking of stretching the material.

Yet another object of the invention is to provide in such a machine means for forming a casing or ring around the so wrapped alternating layers.

With the above and other objects in view, which will appear as the description proceeds, this invention resides in a novel construction combination and arrangement of parts substantially as hereinafter described and more particularly defined by the appended claims, it being understood that such changes in the precise embodiment of the invention herein disclosed may be made as come within the scope of the claims.

In the accompanying drawings:

FIGURE 1 is an isometric view showing the novel machine as a Whole;

FIGURE 2 is a top view of the machine with portions of the machine being omitted for clarity;

FIGURE 3 is an enlarged front view of a portion of the machine showing the feeding and winding means for the metall foil and the absorbent paper;

FIGURE 4'is a front view showing the means for supplying the casing for the anode;

FIGURE 5 is an enlarged view in partial cross section 3,416,215 Patented Dec. 17, 1968 of the means to wind the casing and to eject the completed anode from the machine;

FIGURE 6 is a partial, enlarged view of the means into which the anode is wound; and

FIGURE 7 is an enlarged view in partial cross section of the anode Winding means.

Briefly, according to the invention, the winding machine includes individual metal foil and absorbent paper supplies adapted to feed strips into a spiral winding to form alternate layers of the foil and paper. Prior to being wrapped together with the paper, the metal foil, which serves as the anode material, passes through means to corrugate the metal foil. The foil strip and the paper strip are wrapped into a spool to form the anode within one of a plurality of apertures formed in a rotatable indexing turret, the paper strip serving as the spool core. As the metal foil strip enters the aperture to be wound, a loop in the foil is developed to prevent tension on the free length of the foil then cut to a predetermined length suflicient to form the size anode desired. Additionally, a particular feature of the invention is the provision of a source of air under pressure directed against the free loop of foil so as to direct it against a curved surface for insuring proper guidance of the foil into the wrap. This feature not only insures that the foil will be properly fed to the wrap, but it also eliminates the tension on the foil that would be built up if the foil were fed to the wrap through a chute of other type conveyor.

Once the spool of alternating layers of spirally wrapped metal foil and paper is completed the indexing turret is indexed to the next aperture, and the operation is repeated. As the turret is indexed, completed anodes are brought into alignment with a source of easing strip adapted to be fed onto the anode to form a relatively tightly Wound casing around the anode. Means are provided to cut the strip and to heat seal the ends of the strip together.

Referring now to FIGURE 1 for a more detailed description, the winding apparatus as a whole is carried by a portable cabinet 10, the cabinet having disposed within it assorted wiring and motor drives for operating the machine. The cabinet also has a control panel 11 having the usual control dials and indicators.

Reel 12 which is attached to the cabinet carries an absorbent paper strip 13 which can be fed to one of the plurality of apertures 14 formed in indexing turret 15, the apertures having a slot or opening 14a cut into the rim 16 of the turret. Reel 17 carries a metal foil 18 such as zinc which can also be fed to the apertures 14. Prior to being fed to the apertures, the foil is first cleaned by passing the strip through a suitable bath 19, the strip being guided through the bath by wheel 20. A suitable liquid for cleaning zinc strip would be trichloroethane, for example. Upon leaving the bath, the strip is then wiped substantially dry and clean through cloth wipers 21.

From the wipers 21, the metal foil proceeds to mutally cooperating corrugating rolls 2.2, the adjustable rolls being held within a housing 23, and being driven by a motor (not shown) through a sheave 24 and belt 25, and electric clutch-brake 46, other appropriate belts and sheaves not being shown. The rolling corrugating action produced by the corrugating rolls 22 pulls the foil strip from the reel 17, the strip being additionally guided over guide pins 26 and 27 which are rotatably held in mounting plate 28. From the corrugating rolls, the foil passes to indexing turret 15 by way of chute 29 to be rolled with the strip of absorbent paper in one of the apertures 14 of the turret.

Referring to FIGURES 1, 2 and 3 the absorbent paper strip 13 is initially fed to one of the apertures 14 through motor driven rolls 30 and 31, the strip being passed over plate 32. Roll 31 has a friction drive surface 33 such that the strip is fed in steps, the length of strip being fed in a single step being equal to the arc length of the surface 33. This length is substantially equal to the distance between points A, B, point A being the center of the aperture 14 and point B being the point where knife 34 cuts the absorbent paper strip. Thus, While the rolls and 31 are continuously rotating, the speed of the rolls are timed such that drive surface 33 engages the absorbent paper strip after an anode has been formed within the aperture 14 and the next succeeding aperture is indexed into position. In addition the length of paper fed to the aperture 14 serves as the core around which the alternating layers are wrapped to form a spool.

Metal foil strip 18 is fed to the axis of aperture 14 as it passes from corrugating rolls 22 by way of chute 29. As theend of the metal strip reaches the axis of the aperture it is mated to the absorbent paper strip 13 through a pair of retractable, and rotatable fingers 35 and 35a, the fingers being connected to a motor (not shown) through electric clutch-brake 119, through belt 121 and sheave 120, through sprocket 122 and chain 123 to friction clutch-sprocket 126. When the metal foil strip reaches a predetermined length, knife 39 shears or cuts the strip against cutting block 40, the knife being actuated through solenoid 41 which is controlled by a revolution counter 59, the counter being in sequence to the corrugating rolls 22 through pulley and belt 24a and 25a. The severing of the strip immediately reduces the tension in the relatively thin, fragile strip that would normally be created by the pull against the corrugating rolls as the foil is wound. Additionally, a particular feature of the machine lies in the provision of a source of air to force the fragile strip off the base of the chute 29. To this end, an aperture 43 is provided in the base of the chute to which a hose 44 is connected. Air under pressure is then directed against the strip from an external source (not shown) through the hose, the hose being connected to a solenoid valve (not shown) that is pulsed from timer 45. The so directed air forces the strip to form a loop 47 between guide rod 48 and guide surface 49 formed in guide element 50. Guide element 50 is rotatably connected to mounting plate 28 such that the guide surface 49 can be properly adjusted.

With particular reference to FIGURES 2 and 3, while the strips are being engaged with the pair of fingers 35 and 35a alignment of the strips is aided by a pair of guide bars 51 and 52 which are held in spaced relationship through housing 53. As the winding proceeds the guide bars are moved away from the strips through a bar 54 which is attached to associated drive means within gear box 36, the driving means within the gear box being driven by a main chain drive 38 through shaft 37. Spring steel fingers 35 and 35a are separated (FIGURE 7) to accept absorbent paper 13 and the corrugated metal foil 18. Position of fingers 35 and 35a is established by solenoid operated stop 127 controlled by timer 45 (FIGURE 1) and indent collar 124 through clutch-sprocket 126. Fingers 35 and 35a are retracted through bushing 101, held within cup 100, by actuating shaft 102 through solenoid 125 thus reducing the diameter of fingers for removal from the completed anode.

Continued rotation of the fingers 35 and 35a completes the winding of the strips to form alternate layers of the strips in the form of a spool. The completed anode is more readily shown in FIGURE 4. As shown the anode consists of alternate layers of the corrugated metal foil 18 and the absorbent paper 13, there being a few additional layers 57 of the paper at the outer rim to add structural stability to the spool.

Upon completion of the winding, the absorbent paper is cut or severed through knife 34, the knife being controlled through a solenoid 55 (FIGURE 2) which is carried by stand 58 (FIGURE 1) the solenoid being in electrical connection to revolution counter 42 (FIGURE 1). It should be understood that the length of foil cut is such that when synchronized with the timing of the cutting of the paper, there will be sufficient paper to add the few extra outer layers previously noted with reference to FIGURE 4. After the complete winding of the anode is accomplished, fingers 35 and 35a are retracted by solenoid 125 timed by timer 45, the anode being held by inner surface of aperture 14 and against face 100a (FIG- URE 7). Turret 15 is then indexed through shaft 61 (FIGURE 2), the shaft being connected to the appropriate cams and motor in gear box 36.

Continued indexing of the turret 15 carries a given completed anode into alignment with means .62 and 63 (FIGURES 1 and 4) for applying a suitable binding strip to form a casing around the spool for adding structual stability to the anode. A suitable binding material to form the casing would be polyethylene, for example. Referring to FIGURES 1, 2, 4 and 5 the material to be used as the casing is fed in strips from supply reel 64 through the guide plates 65 and 66, the plates having slots 67 and 68 through which idler roll 69 and driver roll 70 can be extended to meet the drive casing strip 71. Driver roll 70 has a friction drive surface 72 such that a predetermined length of easing strip can be advanced beyond cut-off knife 73, the length being sufiicient to completely wrap the outer periphery of the mandrel 79. Thus, the strip 71 is driven by friction surface 72 down between guide bar 74 and guide plate 75 to the mandrel 79, both of which are bent at the ends 76 to direct the strip to mandrel 79.

Aperature 14 containing spirally wound anode 60 is indexed in alignment with disc 78 and easing winding mandrel 79. Disc face 78a is axially advanced to contact anode 60 thru a cam connected in gear box 36 forcing anode face 60a to project approximately /s of its width past face 150 of indexing turret 15. Simultaneously casing winding mandrel 79 is advanced axially to allow ,rnandrel face 79a to come into contact with anode face 60a. This is done in the following manner: While turret 15 is continually indexing anodes into position for application of the casing, shaft 81 (FIGURE 2) is continually turning through gear box 36. The continual rotation causes cam 82 to .axially index tubular shaft 83 through cam working surface 84 turning against cam roller 85, there being a direct connection to shaft 83 from cam roller 85 through housing 86. The disc 78 is brought to bear against face 60a of anode 60 (FIGURE 5) thus causing both disc and mandrel to bear against the side of the anode. Casing strip 71 is now ready to be applied to the mandrel 79 with some overlap onto the anode 60.

Casing 71 feeding through guide bar 74 and guide plate 75 is grasped by mandrel 79 through vacuum ports 79!), the vacuum being externally supplied through flexible hose-111 (FIGURE 1) and shaft 83. The application of the vacuum is controlled through electricially operated solenoid 110, timed by timer 45. Casing strip 71 is then cut by knife 73 which is actuated by solenoid 73a (FIG- URE 1) that is timed from timer 45 so as to be cut to its required length.

The outer casing is completed through rotation of the mandrel 79 in a manner hereinafter described. After the casing has been applied, heating means 77 is actuated to be moved closer to the mandrel by cam 114 (FIGURE 2) mounted on continuously revolving shaft 81 driven by means located in gear box 36. Heating means 77 may consist of any type heater known in the art such as a resistance heater, for example. Referring to FIGURE 1 the heat is directed against the casing to heat seal the ends of the casing together with the end of hot air, the air being supplied under pressure from a source (not shown) through flexible hose 113. The air is pulsed by timer 45 actuating solenoid 112.

Referring to FIGURES 2 and 5, once the disc 78 and mandrel 79 are brought to bear against the sides of the spool of anode 60, mandrel 79 is rotatably driven through clutch driven gear and pinion drive 87 and 88, controlled by indent 115 on shaft 83 through stop 116 from cam surface 117, the clutch being engaged after disc 78 and mandrel 79 are brought into bearing relationship with the anode. After rotating the mandrel 79 360 the clutch becomes disengaged while the cam working surface 84 causes mandrel 79 to be retracted and simultaneously disc 78 advances through aperture 14 in axial unison with mandrel 79 thus causing edge 71a of the casing to contact face 118 allowing anode 60 to slip inside of the casing. Face 79a being level with face 118, disc 78 is retracted allowing anode 60 to fall by gravity to chute 91 (FIGURE 1).

As can more readily be seen with reference to FIG- URES 5 and 6, indexing turret 15 contains a plurality of slots 89 which are so positioned that a corresponding plurality of tabs 90 extending from disc 78 can be engaged in them. Thus when disc 78 is moved into aperture 14 of the turret 15 tabs 90 engage slots 89. This en sures that the entire anode will be ejected from the aperture without distortion of the anode. As previously discussed, the ejected anode then falls through chute 91 (FIGURE 1).

Thus there is described a completely automatic winding machine which is particularly adaptable to the handling to the fragile strips of material without fear of breakage. Further, from the description taken in connection with the drawings, it will be apparent to those skilled in the art that this invention provides a new and improved winding machine, the features of which may be applied to other arts and devices. Accordingly it is contemplated that the scope of the invention is to be determined from the claims herein.

What is claimed is:

1. A winding machine adapted to form alternate layers of a metallic foil and an absorbent paper material to form an anode in a casing, said machine comprising:

(a) individual supply reels providing a source of sup ply for a metal foil strip, and a strip of absorbent paper material;

(b) motor driven metal foil corrugating rolls for corrugating said metallic strip and for pulling said strip from said supply reel;

(c) means to feed the so corrugated metal strip to a strip winding means;

(d) sequentially timed cutting means for cutting a pre determined length of said corrugated metal foil;

(e) roller drive means for intermittently feeding a predetermined length of said absorbent paper strip to said foil winding means;

(f) means to direct a source of air under pressure at the free end of the cut, corrugated metal strip so as to form a tension free length of said strip;

(g) sequentially timed cutting means for cutting said absorbent paper strip after said metal foil strip and said absorbent paper strip have been wound on said winding means in alternating layers to form an anode in the form of a spool of such layers;

(h) means to index the so formed anode to become aligned with means for applying a casing around said anode, said means comprising a supply reel for feeding a strip of casing material, drive rolls adapted to intermittently feed a predetermined length of said strip to said anode, means to apply said casing about said anode, sequentially timed cutting means for cutting said casing, and sealing means to effect a connection between the ends of said strip; and

(i) means to eject the completed anode with its casing from said indexing means.

2. An automatic winding machine for forming a battery anode in the form of a spool consisting of alternating, spirally wound layers of a corrugated metallic foil and strips of an absorbent paper in a casing, said machine comprising:

(a) a cabinet for carrying the winding apparatus and having a control panel for regulating such apparatus;

(b) individual supply reels for the said metal foil and said absorbent paper;

(c) a cleaning bath for cleaning said metal foil and Wipers for wiping said foil after cleaning;

(d) a pair of cooperating corrugating rolls for corrugating said metal foil, said rolls being rotatably power driven so as to pull said foil through said cleaning bath and said wipers from said supply reel;

(e) a chute to feed said corrugated foil to an indexing turret, said turret having a plurality of apertures positioned near its outer periphery and having slots forming openings between said apertures and the rim of said turret for receiving said metal foil and said absorbent paper;

(f) a sequentially timed cutting knife for cutting said metal foil after being fed to said aperture but prior to winding said strip;

(g) means to direct a source of air under pressure through at least one aperture disposed in said chute so as to lift said foil off of said chute and direct it against means to form a loop of the free end of said cut foil;

(h) a pair of cooperating feed rolls for feeding said absorbent paper from its supply reel to the same aperture in said turret receiving the metal foil, said rolls being power driven, and one of said rolls having a friction driving surface adapted to intermittently feed a predetermined length of said paper to said aperture;

(i) a pair of rotatable fingers extending into said aperture of said turret for receiving said corrugated metal foil and absorbent paper, power driving means for rotating said fingers so as to Wind said foil and paper spirally around said fingers to form said anode in the form of a spool, and sequentially timed means to retract said fingers from said aperture after said winding is completed;

(j) a sequentially timed cutting knife for cutting said paper after said winding is completed;

(k) means to rotatably index said turret;

(l) a supply reel for a strip of casing material to be applied around said spool;

(m) a pair of cooperating power driven rolls, one of said rolls having a friction driving surface for intermittently feeding a predetermined length of said casing material to said spool;

(n) means to apply said casing about said spool;

(o) sequentially timed cutting means for cutting said casing;

(p) sealing means to effect a connection between the ends of said strip; and

(q) means to eject the completed anode with its casing from said indexing turret.

3. An automatic winding machine according to claim 2 wherein said means to apply said casing about said spool and said means to eject said completed anode from said indexing turret comprises:

(a) a mandrel axially aligned with a rotatable disc, both being disposed in spaced relation such that an aperture of said indexing turret carrying a completed spool can be axially aligned between the two;

(b) means to axially advance said disc against a face of said spool so as to advance a portion of the spool out of said aperture;

(c) means to alternately advance said mandrel against the opposite face of said spool, to rotate said spool, and to retract said spool after its rotation is complete;

(d) said mandrel having means to hold said casing to said mandrel during its rotation; and

(e) means to alternately further advance said rotatable disc while said mandrel is retracted and then to retract said disc whereby said spool slips into said casing and said spool with its casing is ejected from said aperture of said indexing turret.

4. An automatic Winding machine according to claim 3 wherein the means to hold said casing to said mandrel comprises a plurality of ports formed in said mandrel and means to supply a vacuum pressure to said ports.

5. An automatic Winding machine according to'claim 2 wherein said sealing means includes an electric resistance heater, means to advance said heater to the casing wrapping means, and means to supply air in a pulsing mode to said heater.

3 wherein said rotatable disc has a plurality of tabs posi- References (Iited UNITED STATES PATENTS 2,242,022 5/1941 Blount et al. a- 29-203 2,624,106 1/ 1953 Lund 29204 3,331,724 7/ 1967 Balaguer 29-204 THOMAS H. EAGER, Primary Examiner.

US. Cl. X.R. 

1. A WINDING MACHINE ADAPTED TO FORM ALTERNATE LAYERS OF A METALLIC FOIL AND AN ABSORBENT PAPER MATERIAL TO FORM AN ANODE IN A CASING, SAID MACHINE COMPRISING; (A) INDIVIDUAL SUPPLY REELS PROVIDING A SOURCE OF SUPPLY FOR A METAL FOIL STRIP, AND A STRIP OF ABSORBENT PAPER MATERIAL; (B) MOTOR DRIVEN METAL FOIL CORRUGATING ROLLS FOR CORRUGATING SAID METALLIC STRIP AND FOR PULLING SAID STRIP FROM SAID SUPPLY REEL; (C) MEANS TO FEED THE SO CORRUGATED METAL STRIP TO A STRIP WINDING MEANS; (D) SEQUENTIALLY TIMED CUTTING MEANS FOR CUTTING A PRE DETERMINED LENGTH OF SAID CORRUGATED METAL FOIL; (E) ROLLER DRIVE MEANS FOR INTERMITTENTLY FEEDING A PREDETERMINED LENGTH OF SAID ABSORBENT PAPER STRIP TO SAID FOIL WINDING MEANS; (F) MEANS TO DIRECT A SOURCE OF AIR UNDER PRESSURE AT THE FREE END OF THE CUT, CORRUGATED METAL STRIP SO AS TO FORM A TENSION FREE LENGTH OF SAID STRIP; (G) SEQUENTIALLY TIMED CUTTING MEANS FOR CUTTING SAID ABSORBENT PAPER STRIP AFTER SAID METAL FOIL STRIP AND SAID ABSORBENT PAPER STRIP HAVE BEEN WOUND ON SAID WINDING MEANS IN ALTERNATING LAYERS TO FORM AN ANODE IN THE FORM OF A SPOOL OF SUCH LAYERS; (H) MEANS TO INDEX THE SO FORMED ANODE TO BECOME ALIGNED WITH MEANS FOR APPLYING A CASING AROUND SAID ANODE, SAID MEANS COMPRISING A SUPPLY REEL FOR FEEDING A STRIP OF CASING MATERIAL, DRIVE ROLLS LENGTH OF SAID INTERMITTENTLY FEED A PREDETERMINED LENGTH OF SAID STRIP TO SAID ANODE, MEANS TO APPLY SAID CASING ABOUT SAID ANODE, SEQUENTIALLY TIMED CUTTING MEANS FOR CUTTING SAID CASING, AND SEALING MEANS TO EFFECT A CONNECTION BETWEEN THE ENDS OF SAID STRIP; AND (I) MEANS TO EJECT THE COMPLETED ANODE WITH ITS CASING FROM SAID INDEXING MEANS. 